This chapter is discuss and compile information that is related to this final year project which is about the lean production system practice at automotive industry by using one of the lean tool which is standardized work kaizen to improve productivity and reduce production time. In this chapter will briefly discuss about the history and introduction about the Lean Production System. There are 7 type of deadly waste that listed by TPS and with the elaboration of Muda, Mura, Muri. The TPS House Diagram illustrates the manufacturing system and the Malaysia Japan Automotive Industries Cooperation (MAJAICO) program created to improving the Malaysia Automotive Industries. The element in the standardized work is takt time, cycle time, …show more content…
Industrial competitiveness needs technological capability and developing higher technological innovation. Malaysia Japan Automotive Industries Cooperation (MAJAICO) is a program created to improving the Malaysia Automotive Industries to be more competitive in world market. The main agenda is to increase the productivity improvement by inventory reduction, develop local lean expert, die change saving time and inventory reduction. The long term strategy in future is to ensure local automotive company can conduct the LPS program by themselves without assist by Japanese LPS expert and develop lean culture in all Malaysia Automotive industry.(Fahmi,2012) Sapura Machining Corporation Sdn. Bhd. is one of the automotive industries that follow this program that was initiated under Malaysia Japan Economic Partnership Agreement (MJEA) by applying Lean Production System (LPS) in their company. The implementation of LPS is being evaluated in this program. The target is both supplier and automotive maker to upgrade their quality and technology level. Local supplier required to improve the quality, cost and delivery (QCD).(Sadoi,
In today’s operational management arena, there are certain expectations from a managerial aspect that must be met in order to be successful. A comprehensive look at the Space Age Furniture Company will show exactly what the Materials Requirement Planning (MRP) calculations are for this company at present time and then take the information given in order to properly suggest ways to improve the sub-assemblies. In addition, there will be an analysis on the trade-offs between the overtime and inventory costs. A calculation will be made on the new MRP that will improve the base MRP. This paper will also compare and contrast the types of production processing to include the job shop, batch, repetitive, or continuous, and determine which the primary mode of operation should be and exactly why. A detailed description on how management can keep track of the job status and location during production will also be addressed. Finally, there will be a recommendation on they type of changes that need to occur that will be beneficial to the company and at the same time add value to the customer. This paper will conclude with summary of the major points.
TPS is based on the concept of Heijunka, evening out production to meet the fluctuations of demand and eliminating unnecessary inventory. Heijunka focused on eliminating waste, as it related to overproducti...
Based on future supplier contracts, shortening lead time for delivery of parts and materials establishing leaner processes, namely addressing wastes identified through implementing a Just-In-Time (JIT) system. A centralized wharehouse system, co-located near the manufacturing plant will reduce shipping and transportation costs or look for larger space with warehousing capacity. Savings, significant enough will be a factor if space with warehousing falls within the
“The Goal” is a book talking about challenges and problems that can face any plant manager. The story style used was very useful. I enjoyed the reading and gain more knowledge about the manufacturing operation. Many concepts and definitions were introduced such as the goal of any company and the its three measurements which are throughput, inventory and exponential expenses. Also, bottleneck and non-bottleneck resources.
Lean manufacturing refers to systematic identification and elimination of waste through CI processes in pursuit of perfection (Khan et al. 2013; Yang & Yang 2013). Lean production is now used worldwide in manufacturing plants to eliminate waste from all ar...
During this project, I am going to mention the details of TOYOTA production process system which was developed more than 40 years ago by Taiichi Ohno, the president of Toyota Motor company at that time. The production system that Toyota company uses now and before is relevant to the concept of the process costing system which is currently used in all department of the company.
The just-in-time (JIT) inventory system was developed in Japan after World War II, in an effort to control costs during fiscally challenging economic times (Waguespack and Cantor, 1996). The challenge that faced many Japanese companies in the post-War era was to find a way to meet the needs of customers and businesses while utilizing as few resources and as little capital as possible. The Japanese developed these set of techniques in order to control production, limit unnecessary products and reinvest the valuable capital left from the savings back into the business structure (Waguespack and Cantor, 1996). Much of the success of many Japanese corporations over the past four or five decades has been was linked to the principles of JIT (Chhikara and Weiss, 1995).
(The origin of the Toyota production system, n.d.). These ideals led to the Just-in-Time method, which is a practice of only making what is needed, when it is needed, using only the amount needed. Just-in-Time is incorporated within the continuous improvement method being that if all elements are performed efficiently and effectively, then it is evident that the corporation will have a lesser chance of becoming stagnant. Their ability to focus on research and development allows them to keep their technological advantage at bay amongst their products, which in turn leads to innovation and sales.
The main goal of every organization is to make maximum profit. There are many factors to be considered when thinking about how to make the biggest profit. Sales contribute to profit but they account for only a small percentage. There are other ways to increase profitability even before products are available for sale. Muda or waste reduction is one of the most practical ways to increase the profitability for any organization. Muda is a Japanese term which literally means futility; uselessness; idleness; superfluity; waste; wastage; wastefulness also known as the “seven wastes”. Taiichi Ohno, Chief Engineer of Toyota between 1948 and 1975 developed the seven deadly wastes as the center of the Toyota Production System (TPS). Toyota Production System is based on the principles of kaizen, continuous improvement and genchi genbutsu, go to source to find the facts to make correct decisions. The Toyota Production System is the precursor to what we understand today as lean manufacturing. Lean manufacturing goal is the elimination of wastes. In order to eliminate waste one must first understand what it is. In this paper I will briefly go through the seven deadly ways and provide some countermeasures for the seven deadly wastes.
Just In Time production concepts originated in Japan, and are generally associated with the Toyota motor company. JIT was initially known as the “Toyota Production System” and its originator was Taiichi Ohno. Ohno examined American manufacturing and devised a new system of production based on the elimination of waste.
Lean production system in applied in the normal manufacturing process and can be explained as follows.
Which aspects of the discussion in this section did you find most interesting? Please try to state why you found this to be the case.
• While making a methodology is challenging, executing it is considerably more troublesome. Numerous organizations comprehend Toyota Production System now, yet at the same time think that it is troublesome to execute and implement.
Toyota has implemented many different systems such as performance monitoring software, the Just in time (JIT) inventory system, electronic quality control system, communication system and information system thought out their value chain which enable to make correct decision during the manufacturing process. They have identified that having large inventories of spares cost them extensive capital and they have implemented the Just in time (JIT) inventory system which advices the suppliers the exact spares that the product line required and provides a time frame. Toyota adopted continuous learning and embraces change allowing their staff to research and innovation (Toyota
Scheduling of production plays an important role in the scheduling and planning of modern manufacturing systems [1]. Production scheduling includes allocating the resource over a timeframe to carry out an assortment of tasks, which is one of the most critical issues in the managing and planning of processes of manufacturing. In a production system, various kinds of scheduling problems are studied and Job Shop Scheduling Problem (JSSP) is one of the most difficult problems in this area. [2].